Mainshaft Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Suzuki Reno, 2007 Suzuki Forenza, 2006 Suzuki Reno, and 2006 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Remove the mainshaft bearing using the universal bearing puller J-22912-01.

Fig 1: Removing Mainshaft Bearing
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Remove the snap ring.

Fig 2: Identifying Snap Ring
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Remove the 1st gear, the flat-type 1st-gear needle bearing, and the mainshaft wear plate.

Fig 3: Removing 1st Gear, Flat-Type 1st-Gear Needle Bearing, And Mainshaft Wear Plate
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Remove the synchronizer hub sleeve that contains the synchronizer spring.
Remove the outer blocking ring.

Fig 4: Removing Outer Blocking Ring
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Remove the keys from the 1st - 2nd synchronizer gear.

Fig 5: Identifying Keys Onto First-Second Synchronizer Gear
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Remove the barrel-type 1st-gear needle bearing.

Fig 6: Identifying Barrel-Type First-Gear Needle Bearing
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Remove the snap ring and the washer.

Fig 7: Identifying Snap Ring And Washer
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Remove the 1st - 2nd synchronizer gear from the mainshaft.

Fig 8: Removing 1st - 2nd Synchronizer Gear From Mainshaft
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Remove the 1st - 2nd gear blocking ring.

Fig 9: Identifying First-Second Gear Blocking Ring
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Remove the 2nd gear using the universal bearing puller J-22912-01.

Fig 10: Removing Second Gear
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Remove the 2nd-gear needle bearing.

Fig 11: Removing Second-Gear Needle Bearing
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Remove the ring and the thrust washer.

Fig 12: Removing Thrust Washer And Ring
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Remove the 3rd gear and the synchronizer blocking ring.

Fig 13: Removing 3rd Gear And Synchronizer Blocking Ring
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Separate the synchronizer blocking ring from the 3rd gear.

Fig 14: Separating Synchronizer Blocking Ring From 3rd Gear
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Remove the 3rd-gear needle bearing from the mainshaft.

Fig 15: Identifying Third-Gear Needle Bearing
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Remove the synchronizer sleeve containing the keys and the spring.

Fig 16: Identifying Synchronizer Sleeve Containing Keys And Spring
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Remove the snap ring and the washer from the mainshaft.

Fig 17: Removing Snap Ring And Washer From Mainshaft
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Remove the 3rd - 4th synchronizer gear containing the synchronizer spring.

Fig 18: Identifying Third-Fourth Synchronizer Gear Containing Synchronizer Spring
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Remove the 4th-gear assembly.

Fig 19: Identifying Fourth-Gear Assembly
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Separate the synchronizer blocking ring from the 4th gear.

Fig 20: Separating Synchronizer Blocking Ring From 4th Gear
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Remove the 4th-gear needle bearing, the ring, and the thrust washer.

Fig 21: Removing 4th-Gear Needle Bearing, Ring, And Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft bearing.

Fig 22: Removing Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.